Method of molding hollow objects



Aug. 26, 1924.

W. HENKER METHOD OF MOLDING HOLLOW OBJECTS Filed Aug. 5, 1922 atented Aug. 26, 1924.

To allwhomitmay concern.

' Be it known that I, WILLY HENKER, a

the county of Brandenburg and State of Prussia, Germany, have invented certain new and useful Im rovements in Methods of Molding Hollow bjects, of which the following IS a specification.

My invention relates particularly to "a process of moldin objects from compositions containing su phur and abrasive blast.- ings of metal castings and. the product theretion of products. which. may be-provided with thick hollow walls and to producing products having smooth internal surfaces.

The object of my invention is particularly to provide a process of producing molded objects from compositions containing sulphur and abrasive blastings of metal castings,-and the product thereof, but my process is so conducted that objectsmay be cast with thick walls without danger of crack ing due to expansion from the hardening of a residual internal mass of the molten material. A further object is to provide a process of molding with compositions of this character in such a manner as to produce products having smooth internal surfaces.

the invention as described in and covered by my application upon process of molding and product thereof filed on even dateherewit i I Further objects of my invention 'will appear from the detailed description thereof contained hereinafter.

My invention is capable of embodiment in many different'forms and may be carried out with many different kinds of apparatus, but by way of illustration I have shown only'one type of apparatus for use in connection therewith 1n the accompanying drawings, in which- Figure 1 is a vertical section of a molding apparatus for use in connection with my invention.

Figure 2 is a side elevation of the combined core andcover used therewith, and

Figure 3 is a vertical section of a cover used at the end of my process as hereinafter described.

which in this instance is comprised of upper and lower annular portions 1 and 2 citizen of Germany, a resident of Berlin, in

of but is especially applicable to the produc Thisinven-tion is a further'ela-boration of j.

' In the drawings II have shown a mold UNITED STATES PATENT OFFICE,

wILLY' nnnxnn, or BERLIN, Granary, assmnoaro ART iunusrams, INCL, a

coarona'rronor NEW YORK.

' METHQT) OIi MOLDING HOLLOW OBJECTS.

which may be of any desired metal as, for example, 1ron, brass,etc., having located be-v tween them. a separable ring 3 of similar material rovided with annular projections 4 and 5 tting in similarlyshaped recesses 1n the parts of the-mold l and 2'. Thering 3 hasa surface 6 carrying a design to mold a 7 upon the completed product, whlch inthis instance is shown as a jardinire' 8. The lower portion of the mold is closed by a combined cover and core 9 which has an 'upwardly directed ,frustoconical core 10 with a smooth external surface,

which will provide a smooth surface for the interior of the molded product 8. This may be made of a material similar to that used in the other portions of the mold. At the top of the mold there is a funnel-shaped cover 11, also made of similar material, which fits in the annular portion 1 of the mold. When the process has been partially completed as hereinafter described said funnelshaped portion is removed and substituted by a cover 12, also of similar material, having aprojection 13 fittin .into the annular portion 1 of the mold an -which is slightly shorter than the corresponding portion on the funnel-shaped member 11.

' The composition for the molding operation is nowprepared by melting a mixture containing for example approximately 53 parts by weight of finely divided sulphur and approximately 47 parts by weight of the sand blastings from metal castings, such, for example, as sand blastings from iron, brass or copper castings. These sand blastr ings are: comprised of particles of sand,

each of which has attached thereto as a coating or otherwise, minute portions of the metal from whichthefcasting is made. To

thismolten mass maintained at any desired temperature to produce a homogeneous liquid, but preferably at a temperature of about 122? 0., there is added a melted mixture of double the quantity of approximately 45 parts by weight of pulverized magnesite and approximately 55 parts by weightof pulverized sulphur heated to molten state but preferably to a temperature of 200 C. Preferably the-second molten mixture is at a higher temperature than the first although this is not. essential, as the composition containing magnesite is more viscous than the other composition to be mixed therewith. It will be understood that the metalliferous 25 form of mineral and the core 10 will serve referredto is used by'rubbing thesurface l 50 bottom of the cover 11,thus leaving asmall above in detail I wish it to be understood Q p j 1,506,062

sand may be comprised of the mineral blastavoided. When the object-has entirely hardings of any desired character obtained by sued the mold is removed and it will be blasting any metal castings such as steel, found that the product will have a smooth iron, copper or brass castings with any interior. Any traces of the junction points finely divided abrasive material such, for of the mold upon the object'may be removed example, as sand. Also it will be underby grinding or otherwise. It will be found stood that instead of the magnesite any carthat the molded object has-a very highgloss. bonate of an alkali earth met-al may be used If desired the surface of the molded object as, for example, marble, dolomite, etc. It may now be preserved against any change'by will also be understood that substantially polishing the same with a material which any proportions of the ingredients referred will leave an extremely thin coating of such to may be used. g a character as to prevent oxidation. For The mold set up as in'Figure 1 is now this purpose I may use any composition con; ,filled with the moltenmassmade and pretaining a resinuous or waxy material and a pared as described above but if des'ired in solvent as, forexample, a composition conorder to produce an object having an ap-' taining 90% by weight :ofparaflin or bees 'pearance of marble the second composition wax and 10% by weight of rosin, the same. containing the ma nesite or similar material belng dissolved in enough turpentine or maybe introduce alternately with the proether to 'form a cream therefrom." Other portions of'the first mentioned composition. resins may be used aswell as other waxes The filling of the mold is preferably con and other solvents but I have found that the ducted by pouring in the molten material alcohol soluble resinswill not servethedegradually after the interior of the mold has sued purposeito preserve the surface of the; been provided with a thin coating of a pure molded product. Thepresent composition to prevent the molten material from splashof the molded product andthen polishing ing as said material will flow gently down thesa-Ine by rubbingwith any kind of fabric the sides of the same. By avoiding spl'ashdesired. I v k ing the production of imperfections on the When desired, decorativeinlays can be exterior of the molded objects due to premamade in the molded objects by introducing turehardening of the splashed portions on Inlays of thin metal, paper or celluloid,'et c., the mold is obviated. In this way also the Wh ch' a g ed t h nteri r of the mold production of anyair bubbleswhich will before pouring in the molten material. roduce blemishes'on the exterior of the These inlays can besubsequently worked to molded object'is avoided. '.The arrangement produce any desired design with the aid of is such,- furthermore, that the material cancarving, colors, etc. a I t not run down the inner walls of the mold. -Where the forms are separable it will be Also, the mold should. be supported sowas to nders oo thathone om re p m y 7 be free from vibrations. The material is albe changed therein'at will to produce any 40 lowed to harden for a sufficient length of desired form. In this way th num r Of time to produce awall of the solid material different molds required ma be decreased. adjacent to the outer portion of the mold In my application Serial and adjacent to the core 1 0, but leaving it August 5, 1922,. process ofxmoldm liquid portion between the same as shown in product thereof,.I have described'a method Figure 1. This will ordinarily require about of Introducing 1i uid material into a. m. ld one minute. When this stage ofthe process and forming an'o ject therein, the composihas been reached the liquid material still tion 9f said materialbeing similarfto that present in the hollow space referred to is usedm the'present case.

oured out until the level is just below the While I have described my invention portion thereof which is allowed1to remain that man changes may be made therein in the cavity between the walls. The metal without eparting from the spirit of the cover 12 is now applied tothe top of the same. J t mold and the entire mold is inverted and I. claim: i I t allowed to remain in this position until a 1. The rocess which comprises molding further. quantity of the molten material has an object y'pouring 'a molten material i' hardened so as to produce a solid base for a' mold having a core, pouring out molten the jardiniere but leaving the hollow space material therefrom to leave a hollow space as above referred to. By moving the mold when some of the molten material has into different positions from time to time hardened to form external iandf internal the remainder of the molten liquid willbe Walls, then closing the mold to prevent the evenly distributed on the walls of the mold, escape of the molten liquid remaming there thus leaving a hollow space so that the in and allowing the same to harden to close cracking of the product in its final stage, of the hollow space. Y r w cooling, due to the internal pressure, is t 2. The processwhich comprises molding I a mold having a core with a smooth surface,

pouring out molten material therefrom to leave a hollow space when some of the molten material has hardened to form external and internal walls, then closing the mold to prevent the escape of the molten liquid remaining therein and allowing the same to harden to close the hollow space.

3. The rocess which, comprises molding an object y pouring a molten material containing sulphur and mineral blastings of iron castings into a mold havin a core and ouring out molten material vt erefrom to eave a hollow space when some of the molten material has hardened to form external and internal walls, and then closin the opening from which the molten materia was oured.

4. he rocess which comprises molding an object y pouring a molten material containing sulphur and abrasive blastings of metal castings into a mold having-a core, pouring out molten material therefrom to leave a hollow space when some of the molten material has hardened to form external and internal walls, then closing the mold to prevent the escape of the molten liquid remaining therein and allowing the same to harden to close the hollow space.

5. 'The rocess which comprises molding an object y pouring a molten material containing sulphur and abrasive blastings of metal castings into a mold having a core with a smooth surface and pouring out molten material therefrom to leave a hollow space when some of the molten material has hardened to form external and internal walls, and then closing the opening from which the molten material was poured.

6. The 1process which comprises molding an object y pouring a molten material containing sulphur and abrasive blastings of metal castings into a mold having a core with a smooth surface, pouring out molten material therefrom to leave a hollow space when some of the molten material has hardened to form external and internal walls, then closing'the mold to prevent the escape of the molten liquid remaining therein and'allowing the same to harden to close the hollow space.

7. The rocess which comprises molding an object y pouring a molten material containing sulphur and sand blastings of metal castings into a mold having a core. with a smooth surface, and pouring out moltenmaterial therefrom to leave a hollow space when some of the molten material has hardened to form external and internal walls, then closing the mold to prevent the escape of the molten liquid remaining therein and allowing the same to harden to close the hollow space.

8. The Iprocess which comprises molding an object y pouring a molten material contaming sulphur and sand blastings of metal castings into a mold having a core with a smooth surface, pouring out molten material therefrom to leave a hollow space when some of the moltenmaterial has hardened to form externaland internal walls, then closing the mold to prevent the escape of the molten liquid remaining therein and allowing the same to harden to close the hollow space.

9. The process which comprises molding an object pouring a molten material containing su phur, sand blastings of metal castin s and a carbonate of an alkali earth metal into a mold having a core and ouring out molten material therefrom to eave a hollow space when some of the molten material has hardened to form external and internal walls, and then closing the opening from which the molten material was poured.

10. The process which comprises molding an object b pouring a molten material containing su phur, sand blastings of metal castings and a carbonate of an alkali earth metal into a mold having a core with a smooth surface and pouring'out molten material therefrom to leave a. hollow space when some of the molten material has hardened to form external and internal walls, then closing the mold to prevent the escape of the molten liquid remaining therein and allowing the same to harden to close the hollow space.

11. The process which comprises molding an object by pouring a molten material containing sulphur, sand blastings of metal castings and a carbonate of an alkali earth metal into a 'mold having a core with a smooth surface, pouring out molten material therefrom toleave a hollow space when some of the molten material has hardened to form external and internal walls, then closing the mold to prevent the escape of the molten liquid remaining therein and allowing the same to harden to close the hollow space.

12. The process which comprises molding an object by pouring a molten material into a mold having a core, pouring "out molten material therefrom to leave a hollow space whensome of the molten material has hardened to form external and internal walls, then closing the mold to prevent the escape of the molten liquid remaining therein, allowing the same to harden to close the hollow space, and changing the position of the mold from time to time to distribute the molten liquid as it hardens over the different walls of the product.

In testimony that I claim the foregoing, I have hereunto set my hand this 5th day of July, 1922.

WILLY HENKER. 

